DE19903796A1 - Recyclable reusable composite material, used e.g. as a construction, insulating or packaging material or fuel, comprises thermoplastic binder and various filler materials - Google Patents

Abstract

A recyclable and reusable composite material comprises a thermoplastic binder and various filler, functional, residue or waste materials. A recyclable and reusable composite material comprises a thermoplastic plastic binder and optionally various filler materials, functional/structural elements, residual materials or even waste products and can be in the form of a molding, semi-finished product, granules, powder, fibers, foam, building material, additive or jointing element. Preferred Features: The fillers are renewable dry plant products (e.g. wood components, plant fibers, grass or leaves), fossil fuel (coal lumps or dust), glass and/or ceramic (powder, granules, glass fibers, mineral wool, or even cullet), sand, rubble, plastics, paper products, fabrics and/or textiles, metallic materials or other composite materials. Various physical, mechanical and/or chemical properties are achieved within and/or at the surface of the composite material by choice of the material composition, specific fillers, integrated functional elements, production technology and/or process parameters. If required, the material may be subjected to hot shaping or jointing at the place of use. The material may contain contaminated wood particles, in which case the thermoplastic binder prevents or reduces emission of toxic preservatives or solvents. Chemical binders, mixing promoters or resins may be added to obtain stable mechanical and chemical bonding between the thermoplastic and the filler materials. The plastic surface of the material is impervious or has a controlled porosity to allow storage in a moist environment and to allow use as a base for plastic coating, impregnation or preservation of various materials and surfaces.

Description

State of the art

With reference to the prior art, chipboard in particular is known which as Ingredients mainly contain wood chips. Such chipboards are used in one relatively wide range in the home and craft sector.

In most cases, the wood chips in chipboard become hardenable Binder, mostly used on a synthetic resin basis. A later release of these binders can Thermal separation processes sometimes take place with the help of chemical processes which lead to the reusability of chipboard, however, are less well known. The recycling of chipboard in combustion processes, taking into account valid ones Pollutant regulations, due to the binders used, preservatives (e.g. Formalin) or other auxiliaries and carriers can only be carried out with great effort or even impossible.

The composite material on which this description of the invention is based can be the above potentially solve the problems mentioned.

Description of the invention

A recyclable and reusable composite material (also known as a compound) which contains various types of materials (both metals and non-metallic Compounds), functional elements, residues or waste products can contain. As Binders for these ingredients are used primarily in thermoplastics such as. B. PE or PP, which itself is mainly available from a previous recycling process be put.

The fillers that are as dry as possible can be wood chips and wooden parts in general renewable vegetable dry products (e.g. plant fibers, grasses, leaves), fossil Raw materials (e.g. coal parts or coal dust), glass or ceramics (powder, granules, glass fibers, Mineral wool or broken glass), sand, building materials, plastics, paper products, Textiles / fabrics, metallic materials, functional elements or others Composites.

With the help of a defined changeable material composition or a specific one Selection of fillers, variable manufacturing technologies and process parameters (such as  Pressure, temperature-time regime, different shapes) are different physical / mechanical / chemical material properties (such as density, Thermal insulation properties, heat conduction, rigidity, mechanical strength, EMC Shielding, electrical conductivity or insulation, magnetic conductivity, permanent magnetic properties, corrosion resistance) and geometries can be realized. If the manufacturing process z. B. designed so that the ratio open porosity / closed Porosity of the compound is modifiable, the material can be within the limits "Breathable", moisture-insulating and air-impermeable.

If the composite material is used as a building material, semi-finished product or construction material, by modifying the geometry (e.g. by introducing cavities, roughening the surface by forming snap-in-like Connecting elements as well as threads or bearing / guide elements etc.) different specific properties achieved and a wide range of possible Areas of application are opened up. Furthermore, are already in the manufacturing or Forming process additional functional elements / devices can be introduced (e.g. by Pouring, pressing), so that in a subsequent assembly process the manufactured Components / assemblies simplify assembly and save time Assembly effort is possible.

It is also possible that the properties of the composite material depend on the application is modified or structured, d. H. they are in the material or only on the surface specific physical properties of the material possible or also adjustable (e.g. different mechanical strengths, different thermal expansion coefficients, electrically conductive or insulating areas, magnetically or mechanically structured Permanent magnetism, etc.).

There is also the possibility for the material mixture described, in the present case, for. B. as Granules, powder, foam, fibers, building material, additive, connecting element, molded part or Semi-finished product, it is only at the place of use a thermally based molding process or To undergo joining process.

The inclusion in particular of (slightly) contaminated wood particles by the in the The thermoplastic materials to be used according to the invention can outgas of toxic preservatives or solvents of the included  Prevent (contaminated) wood particles in the end product or at least greatly reduce them. This could result in compliance with prescribed emission limits or even fall below what is otherwise extremely problematic or even impossible. Moreover this can result in the recycling and reuse of contaminated wood waste (e.g. chipboard of furniture elements preserved with formalin).

So-called glare promoters (eg "Oxaline" from Henkel) or other chemical agents Binders can also be used if necessary for a more stable mechanical as well as better chemical bond between those primarily resulting from a recycling process, mostly different thermoplastics or their modifications and the fillers / filling elements used are additionally introduced, which in turn leads to Increases the chemical and mechanical stability of the end products.

In this context, the use of the resin components of the introduced wood fillers as an additional binding agent. Chemical binders should be considered all environmentally friendly products such. B. already traditional in wood gluing technology known bone glue connections or latex-based binders are used come.

If the composite material described here is used as a fuel, it is primarily the fillers of the material, primarily consisting of renewable raw materials such as B. Wood waste or / and vegetable fibers used. Because the to be used as a connecting material and processed thermoplastic materials primarily during the combustion process break down into water and carbon dioxide, the resulting waste can environmental considerations. An important requirement, of course, that the material as a whole is free of harmful ingredients or the gaseous and liquid / solid combustion residues comply with the applicable legal limit values.

The freely selectable material composition and geometric shape within certain limits makes such a fuel especially for automatic furnaces in private homes Household or for fully automatic, industrial combustion plants on a larger scale, also in Connection with a cogeneration extremely interesting. So far it is just that different geometric shape from z. B. wood chips or logs a large Problem for the fully automatic feeding into the combustion chamber. The material presented here can solve this problem with a defined and dimensionally stable geometry!  

Another advantage is that the one with a closed plastic surface Fuel (or material) simpler storage even in a damp environment makes possible. The actual fuel (e.g. dry wood components and / or Plant parts) within the material is protected from moisture by the plastic surface protected and consequently the subsequent combustion process can be stabilized as well Process parameters in the combustion chamber of the incinerator are kept relatively constant become. Which in turn makes the incinerator more efficient (compared to strong damp / wet fuels).

The composite material itself is - due to the thermoplastic binders used - recyclable and reusable. The elements and structure produced from such Mixture of materials can in particular by thermal and mechanical separation processes be unlocked again. Chemical separation processes or a combination different separation processes are also conceivable in this context.

POTENTIAL AREAS OF APPLICATION OF THE COMPOSITE

• - In the construction industry as (easy to process) recyclable / reusable filling and Insulation, as a construction additive and as a recyclable / reusable building material: z. B. brick-like individual elements, prefabricated components for prefabricated house construction, connecting elements for Wall and facade constructions, for heat insulation, for sound insulation or for Impact sound insulation in / on / on / under / from walls and floors or as Cladding material for walls, doors and other elements in a wide variety Designs (slabs, tiles, panels or similar).
• - Use in general for recyclable and reprocessable industrial items (such as Linings, housings for computers, as fillers, etc.), for household goods of all kinds, as (low-cost) packaging and filling material (e.g. foamed), Construction elements / cladding elements for furniture, in the car industry or everywhere wherever recyclable materials can be used and where they are to be reused becomes.
• - The inclusion in particular of contaminated wood particles by the in the Plastics to be used according to the invention can outgas toxic  Preservatives or solvents of the enclosed (contaminated) Prevent wood particles in the end product. That way, recycling as well Reuse of contaminated wood waste (e.g. preserved with formalin Chipboard of furniture elements) can be made possible.
• - As a heating medium (e.g. coal-briquette-shaped fuel consisting of fossil and / or renewable vegetable ingredients), the combustion end products must comply with the applicable pollutant regulations. Above all, one must appropriate degree of purity of the starting products. Not or only in one negligible amounts may therefore be present: fats, solvents, Preservatives, chemical additives, heavy metals, etc. The in certain limits freely selectable material composition and geometric shape makes one Fuel especially for automatically populated furnaces and heating systems as well as for Systems with combined heat and power are extremely interesting. Furthermore, it is an uncomplicated one Storage of materials also possible in a damp environment.
• - General for recyclable / reusable items due to their electrical and magnetic properties as a conductive material for EMC shielding, for a magnetic field formation / field line as well as for the discharge of electrical or electrostatic Voltages / charges from / to / used in electrical devices / systems / facilities can be.
• - Recyclable / reusable (low-cost) flooring which also with certain physical properties such. B. EMC shielding can.
• - As a reusable road surface or in general for roads and road construction and for Elements for roads as well as pavement.
• - Plastination, impregnation or preservation of different materials and surfaces (such as wood, paper, textiles / fabrics or others) with the help of mainly recycled as well as reused thermoplastic components.  
• - Due to the free geometric design options of the material, it can be used for architectural elements as well as for sculptures, also possible in an artistic sense.
• - The material described as the subject of the invention is due to its chemical Composition or structure itself recyclable and reusable!

Claims (7)

1. Recyclable and reusable composite material, characterized in that it contains thermoplastic plastics as the base binder and can contain various types of materials, functional / structural elements, residues or waste products as fillers / ingredients and as molded parts, semi-finished products, granules, powders, fibers, Foam, building material, additive, connecting element can be formed and is primarily used for construction materials, building materials, auto parts, packaging, fillers, insulation and for fuels / heating agents. 2. Composite material according to claim 1, characterized in that the fillers of the Composite primarily renewable, as dry as possible plant products (such as Wood components, plant fibers, grasses, leaves), fossil raw materials (coal parts, coal dust), Glass, ceramics (powder, granules, glass fibers, mineral wool or broken glass), sand, Building rubble, plastics, paper products, fabrics / textiles, metallic materials or even other composite materials can be. 3. Composite material according to claim 1 to claim 2, characterized in that with the help a changeable material composition and / or a specific selection of Fillers and / or the integrated functional elements / devices, more variable Manufacturing technologies and / or process parameters different physical / mechanical / chemical material properties and / or geometries / structures both realizable and adjustable within the material as well as and / or on its surface are. 4. Composite material according to claim 1 to claim 3, characterized in that the If necessary, the material is only thermally based at its place of use Shaping process or joining process can be subjected and in this way is brought into its final form. 5. Composite material according to claim 1 to claim 4, characterized in that by a Including in particular of (slightly) contaminated wood particles by the ones to be used thermoplastics the outgassing of toxic preservatives or Solvents of the trapped, contaminated wood particles in the end product are prevented or can be reduced at least to a large extent.   6. Composite material according to claim 1 to claim 5, characterized in that in addition Chemical binders, glare promoters or resins (including those of the used Wood fillers) for a more stable mechanical and better chemical bond between the mostly different ones that result primarily from a recycling process thermoplastics or their modifications and the used Fillers / fill elements lead. 7. Composite material according to claim 1 to claim 6, characterized in that with a closed or adjustable in the porosity plastic surface Material / fuel makes storage possible even in a humid environment and thus furthermore as a basis for plastination, impregnation or preservation of various Materials and surfaces.